Vacuum insulation panel

Abstract

To provide a vacuum insulation panel improved in manufacturability.SOLUTION: A vacuum insulation panel 100 in which a pair of plate materials 1 and 2 face each other to form an internal space Q between them comprises: a metallic first plate material 1; a metallic second plate material 2 that forms an internal space Q between it and the first plate material 1; and a spacer S that supports the first plate material 1 and the second plate material 2 from the internal space Q side. The first plate material 1 has: a first outer edge plate part 12; an upright plate part 13 that is erected from the first outer edge plate part 12 to be formed by a curve surface; and a main plate part 11 that is connected to the upright plate part 13 and is supported by the spacer S. A first resin material 3 having gas barrier properties is interposed between the first outer edge plate part 12 on an outer edge side of the first plate material 1 and a second outer edge plate part 22 on an outer edge side of the second plate material 2. The spacer S is a resin material and is separated from the first outer edge plate part 12 and the second outer edge plate part 22.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present invention relates to a vacuum insulation panel for use in buildings. [Background technology]

[0002] When installing insulated walls in buildings such as houses, buildings, factories, warehouses, etc., they are constructed by installing insulation panels. Insulation panels are obtained by laminating insulation materials in the internal space formed by a pair of facings, or by foaming on site, and vacuum insulation panels, in which the internal space is evacuated, have been known as a structure with better insulation properties. However, with vacuum insulation panels, depending on the material and structure, the facings may deform due to the pressure difference between the internal space and the atmospheric pressure, and the insulation properties may be greatly reduced due to contact between the facings.

[0003] Patent Document 1 discloses a vacuum insulation panel in which the surfaces of a pair of opposing titanium thin plates are each protruded in a roughly hemispherical shape and brought into contact with each other. Patent Document 2 discloses a vacuum insulation panel made of a core material having thermal insulation properties and an outer metal plate covering the periphery thereof, with the inside kept in a vacuum state and sealed at the periphery of the outer metal plate. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] JP 2004-211376 A [Patent Document 2] JP 2013-170652 A Summary of the Invention [Problem to be solved by the invention]

[0005] According to the vacuum insulation panel disclosed in Patent Document 1, the projections abut against each other, thereby suppressing deformation of the titanium thin plate. However, the vacuum insulation panel disclosed in Patent Document 1 has hemispherical projections abut against each other in addition to the outer edge portion necessary for joining, so there is a problem that the insulation performance decreases when the abutting portion is displaced due to time or external pressure. In addition, according to the vacuum insulation panel disclosed in Patent Document 2, the inside is filled with a core material, and the formation of a vacuum layer is not assumed. Therefore, there is a problem that the insulation performance cannot be improved by the vacuum layer. In addition, Patent Documents 1-2 disclose a structure in which opposing metal plates are joined by welding. Here, for example, when welding is performed by bringing a welding tool into a vacuum chamber, the manufacturing cost of the vacuum insulation panel is very high, and there is a problem that the manufacturability is low.

[0006] The present invention has been devised in view of the above-mentioned problems, and an object of the present invention is to provide a vacuum insulation panel with improved manufacturability. [Means for solving the problem]

[0007] The vacuum insulation panel of the first invention is a vacuum insulation panel having a pair of plate materials opposed to each other so that an internal space is formed between them, and comprises a first plate material made of metal, a second plate material made of metal forming an internal space between the first plate material and the second plate material, and a spacer supporting the first plate material and the second plate material from the internal space side, wherein the first plate material has a first outer edge plate portion on the outer edge side, an upright plate portion standing up from the first outer edge plate portion and formed with a curved surface, and a main plate portion that is continuous with the upright plate portion and supported by the spacer, and is characterized in that a first resin material having gas barrier properties is interposed between the first outer edge plate portion and the second outer edge plate portion on the outer edge side of the second plate material.

[0008] The vacuum insulation panel of the second invention is the same as the first invention, wherein the spacer is made of a resin material and is spaced apart from the first outer edge plate portion and the second outer edge plate portion.

[0009] The vacuum insulation panel of the third invention is characterized in that, in the first or second invention, a second resin material having a higher melting point than the first resin material is interposed between the first outer edge plate portion and the second outer edge plate portion.

[0010] The vacuum insulation panel of the fourth invention is characterized in that, in the first or second invention, the spacer has a plate-shaped first support portion extending along the first plate material and supporting the first plate material, a plate-shaped second support portion extending along the second plate material so as to form a hollow space between the first support portion and supporting the second plate material, and a plurality of third support portions supporting the first support portion and the second support portion from the hollow space side, and the plurality of third support portions extend in one direction and are integrally molded with the first support portion and the second support portion.

[0011] The vacuum insulation panel of the fifth invention is the first or second invention, characterized in that the first resin material is interposed only between the first outer edge plate portion and the second outer edge plate portion.

[0012] The vacuum insulation panel of the sixth invention is the vacuum insulation panel of the first or second invention, characterized in that the second plate material has a bent portion between the first outer edge plate portion and the spacer. Effect of the Invention

[0013] According to the first to sixth inventions, a first resin material having gas barrier properties is interposed between the first outer edge plate portion of the first metal plate and the second outer edge plate portion of the second metal plate. That is, the metal plates can be joined together at a temperature lower than the welding temperature. Therefore, the metal plates can be joined together at a lower cost and in a shorter time than with welding tools. This can improve the manufacturability of the vacuum insulation panel. Also, the first plate has a curved upright plate portion. Therefore, the shell structure makes it easy to release external pressure applied to the first plate. This can improve the durability of the vacuum insulation panel.

[0014] In particular, according to the second aspect of the present invention, the spacer is made of a resin material and is spaced apart from the first and second outer edge plate portions. Therefore, the plate members are supported by the spacer made of a resin material having a lower thermal conductivity than metal, and the spacer is less likely to deform or evaporate in the internal space when the plate members are joined because heat is less likely to be conducted from the outer edge side to the spacer. This makes it possible to improve the insulation properties of the vacuum insulation panel while also improving manufacturability.

[0015] In particular, according to the third aspect of the present invention, the second resin material is interposed between the first outer edge plate portion and the second outer edge plate portion. This makes it easier to ensure the thickness of the resin material and makes it harder for heat to be conducted between the plates. This improves the thermal insulation of the vacuum insulation panel.

[0016] In particular, according to the fourth aspect of the present invention, the spacer has a plate-shaped second support portion that extends along the second plate material so as to form a hollow space between the first support portion and the spacer, and supports the second plate material, and a third support portion that extends in one direction and is integrally formed with the first and second support portions. This allows a vacuum layer to be formed in the hollow space. This improves the thermal insulation of the vacuum insulation panel. In addition, the first support portion, the second support portion, and the third support portion can be easily manufactured by extrusion molding or the like. This further improves the manufacturability of the vacuum insulation panel.

[0017] In particular, according to the fifth aspect of the present invention, the first resin material is interposed only between the first outer edge plate portion and the second outer edge plate portion. This makes it easier to suppress the effect of the first resin material being heated and evaporated on the vacuum state of the internal space. This makes it possible to suppress the deterioration of the thermal insulation properties of the vacuum insulation panel.

[0018] In particular, according to the sixth aspect of the present invention, the second plate has a bent portion between the first outer edge plate and the spacer. Therefore, the second plate can deform in accordance with the deformation of the first plate caused by heating, and wrinkles and cracks are less likely to occur. This makes it possible to suppress the deterioration of the thermal insulation properties of the vacuum insulation panel. [Brief description of the drawings]

[0019] [Figure 1] Figures 1(a) to 1(d) are schematic diagrams showing an example of a vacuum insulation panel in this embodiment, where Figure 1(a) is a plan view, Figure 1(b) is a cross-sectional view taken along line AA of Figure 1(a), Figure 1(c) is a partially enlarged cross-sectional view of Figure 1(b), and Figure 1(d) is a cross-sectional view taken along line BB of Figure 1(a). [Diagram 2] Figures 2(a) to 2(d) are schematic diagrams showing a first modified example of a vacuum insulation panel in this embodiment, where Figure 2(a) is a plan view, Figure 2(b) is a partially enlarged cross-sectional view, and Figure 1(d) is a CC cross-sectional view of Figure 2(a). [Diagram 3] 3(a) to 3(d) are schematic diagrams showing second to fifth modified examples of the vacuum insulation panel of this embodiment. [Figure 4] Figures 4(a) to 4(c) are schematic diagrams showing a sixth to eighth modified example of the vacuum insulation panel of this embodiment, and Figures 4(d) to 4(e) are schematic diagrams showing a ninth modified example of the vacuum insulation panel of this embodiment. [Diagram 5] 5(a) and 5(b) are schematic diagrams showing an example of a manufacturing method for a vacuum insulation panel in this embodiment, where FIG. 5(a) is a cross-sectional view and FIG. 5(b) is a partially enlarged cross-sectional view of FIG. 5(a).

[0020] An example of a vacuum insulation panel 100 according to an embodiment of the present invention will be described in detail below with reference to the drawings. In each drawing, a first direction is designated as X, a direction that intersects with the first direction X, for example, perpendicular to it, is designated as a second direction Y, and a direction that intersects with each of the first direction X and the second direction Y, for example, perpendicular to it, is designated as a thickness direction Z. The configurations in each drawing are shown diagrammatically for the purpose of explanation, and for example, the size of each component and the size comparison between the components may differ from those shown in the drawing.

[0021] (Vacuum Insulation Panel 100) An example of a vacuum insulation panel 100 according to this embodiment will be described with reference to the drawings.

[0022] The vacuum insulation panel 100 is used for insulating walls of buildings such as houses, buildings, factories, warehouses, etc. The vacuum insulation panel 100 is used by being fixed to the outdoor side of structural plywood, for example.

[0023] The vacuum insulation panel 100 is constituted by a pair of plate materials facing each other. As shown in, for example, Fig. 1(a) to Fig. 1(d), the vacuum insulation panel 100 includes a first plate material 1, a second plate material 2, a first resin material 3, and a spacer S. The vacuum insulation panel 100 is constituted, for example, by the first plate material 1 and the second plate material 2 facing each other. The vacuum insulation panel 100 exists so as to extend in a planar direction including a first direction X and a second direction Y.

[0024] In the vacuum insulation panel 100, for example, a spacer S is provided in an internal space Q formed between a first plate material 1 and a second plate material 2. In the vacuum insulation panel 100, the first plate material 1 and the second plate material 2 are joined at their outer edge regions via a first resin material 3, and a vacuum layer that is maintained in a vacuum state is formed in the internal space Q.

[0025] Here, the vacuum in the present invention means a state where the pressure is reduced below atmospheric pressure, that is, a negative pressure. More specifically, it means the vacuum described in, for example, ISO 3529-1 or JIS Z 8161-2, and includes low vacuum, medium vacuum, high vacuum, and ultra-high vacuum. By forming the vacuum layer, the heat conduction due to air convection in the internal space Q becomes very small. This makes it possible to improve the heat insulation compared to the area where the plates 1 and 2 contact each other. In addition, with the formation of the vacuum layer, an external force is applied that tries to deform the first plate 1 toward the second plate 2 side due to the negative pressure in the internal space Q, but by being supported by the spacer S, sufficient strength against the external force can be obtained.

[0026] The dimensions of the vacuum insulation panel 100 are, for example, a length in the first direction X of about 1.5 m to 3 m, a length in the second direction Y of about 450 mm, and a thickness in the thickness direction Z of about 8 mm to 20 mm.

[0027] <1st plate material 1> The first plate member 1 has an inner surface facing the internal space Q supported by a spacer S.

[0028] The first plate material 1 is made of a metal such as aluminum or stainless steel (SUS304, etc.).

[0029] The first plate material 1 has a rectangular shape in a plan view, as shown in Fig. 1(a) for example. The first plate material 1 is joined to the second plate material 2 in an outer edge region and is separated from the second plate material 2 in a central region, as shown in Fig. 1(b) for example.

[0030] As shown in FIG. 1(c), the first plate material 1 is made up of a first main plate portion 11, a first outer edge plate portion 12, and an upright plate portion 13, and is joined to the second plate material 2 at the first outer edge plate portion 12 and separated from the second plate material 2 at the first main plate portion 11 and the upright plate portion 13. The first main plate portion 11 is supported by the first outer edge plate portion 12 via the upright plate portion 13. The first main plate portion 11 is formed, for example, in a flat plate shape without any irregularities. The upright plate portion 13 is formed by a curved surface rising from the first outer edge plate portion 12. The first main plate portion 11 is continuous with the upright plate portion 13 and supported by a spacer S.

[0031] For example, the first plate material 1 has an upright plate portion 13 formed with a curved surface. In this case, the shell structure makes it easy to release external pressure applied to the first plate material 1. This improves the durability of the vacuum insulation panel 100. Note that the upright plate portion 13 has a smoothly curved shape and does not have creases, so the curved area is shown shaded in Figure 1(a).

[0032] Here, the surface of the first outer edge plate portion 12 that is the short side of the rectangle and is exposed to the outside is the first main surface f1, and the surface of the first outer edge plate portion 12 that is the long side of the rectangle and is exposed to the outside is the second main surface f2. Also, the surface of the first outer edge plate portion 12 opposite the first main surface f1 and that contacts the second plate material 2 is the third main surface f3, and the surface opposite the second main surface f2 and that contacts the second plate material 2 is the fourth main surface f4. In this case, the first plate material 1 has a resin material (including a first resin material 3 described later) interposed between each of the main surfaces f3 and f4 that contact the second plate material 2 and the second plate material 2, and when the exposed main surfaces f1 and f2 are heated, the resin material melts due to the heat conducted via the main surfaces f3 and f4. Thereafter, the vacuum insulation panel 100 is cooled to solidify the molten resin material, and each of the main faces f3, f4 and the second plate material 2 can be joined by welding.

[0033] The width w1 of the first main surface f1 in the first direction X is, for example, about 20 mm. The width w2 of the second main surface f2 in the second direction Y is, for example, about 20 mm.

[0034] The thickness of the first plate material 1 in the thickness direction Z is, for example, about 0.1 mm to 2.0 mm, and preferably about 0.2 mm. The rising width of the first main plate portion 11 in the thickness direction Z based on the first outer edge plate portion 12 of the first plate material 1 is, for example, about 1.0 mm to 20.0 mm, and preferably about 7.5 mm.

[0035] <Second plate material 2> The second plate material 2 has an inner surface facing the internal space Q supported by the spacer S. As the material of the second plate material 2, the same material as that of the first plate material 1 may be used, for example.

[0036] The second plate 2 has, for example, a rectangular shape in a plan view. As shown in Fig. 1(b), the second plate 2 contacts the outer edge of the first plate 1 in an outer edge region and is separated from the first plate 1 in a central region.

[0037] 1(c), the second plate material 2 is made up of a second main plate portion 21 and a second outer edge plate portion 22, and is joined to the first outer edge plate portion 12 via the first resin material 3 at the second outer edge plate portion 22, and is separated from the first main plate portion 11 and the standing plate portion 13 at the second main plate portion 21. The second main plate portion 21 and the second outer edge plate portion 22 are formed, for example, in a flat plate shape without any irregularities.

[0038] The second plate material 2 may have, for example, an upright plate portion corresponding to the upright plate portion 13. In this case, the second main plate portion 21 is supported by the second outer edge plate portion 22 via the upright plate portion. The second plate material 2 is joined to the first plate material 1 by heating the first resin material 3 on the surface of the second outer edge plate portion 22 and joining the outer edge plate portion and the first outer edge plate portion 12.

[0039] The thickness of the second plate material 2 in the thickness direction Z is, for example, about 0.1 mm to 2.0 mm, and preferably about 0.3 mm.

[0040] <First resin material 3> The first resin material 3 is made of a thermoplastic resin or a thermosetting resin and has gas barrier properties. Here, a resin having gas barrier properties is a resin having an oxygen permeability of 0.001 cm under an environment of a temperature of 23° C. and a humidity of 0% (0% RH) in a gas permeability test described in, for example, JIS K 7126 (Plastics - Films and sheets - Gas permeability test method). 3 / (m 3 ·24h·atm) or less, and water vapor permeability is 0.002g / (m 3 1. The first resin material 3 is a resin film having a gas permeability of not more than 1.0 MPa (24 h). As the first resin material 3, for example, EVOH (ethylene-vinyl alcohol copolymer) or PVDC (polyvinylidene chloride) is used.

[0041] With the first resin material 3 interposed between the first outer edge plate portion 12 and the second outer edge plate portion 22, the outer edge side (for example, the first outer edge plate portion 12 or the second outer edge plate portion 22) is heated, thereby joining the first plate material 1 and the second plate material 2. That is, the metal plates 1, 2 can be joined together at a temperature lower than the welding temperature. In this case, the metal plates can be joined together at a lower cost and in a shorter time than with welding tools. This can improve the manufacturability of the vacuum insulation panel 100.

[0042] The first resin material 3 may be provided, for example, only on the second outer edge plate portion 22 of the surface of the second plate material 2 facing the first plate material 1. That is, the first resin material 3 is interposed only between the first outer edge plate portion 12 and the second outer edge plate portion 22. In this case, it is easy to suppress the influence of the first resin material 3 being heated and evaporated on the vacuum state of the internal space Q. This makes it possible to suppress the deterioration of the thermal insulation property of the vacuum insulation panel 100. In this case, the first resin material 3 may be provided on the third main surface f3 of the first outer edge plate portion 12.

[0043] <Spacer S> As shown in Figures 1(c) to 1(d), the spacer S has a first support portion S1 that supports the first plate material 1, a second support portion S2 that supports the second plate material 2, and a plurality of third support portions S3 that support each of the support portions S1 and S2.

[0044] The first support portion S1 is, for example, plate-shaped and extends along the first plate material 1. The first support portion S1 comes into contact with, for example, a surface of the first plate material 1 and supports the first plate material 1 with the contact surface.

[0045] The second support portion S2 is, for example, plate-shaped and extends along the second plate material 2. The second support portion S2 is spaced from the first support portion S1 so as to form a hollow space R between the second support portion S2 and the first support portion S1. The second support portion S2 contacts, for example, the second plate material 2 or the first resin material 3 on the surface of the second plate material 2, and supports the second plate material 2 at the contact surface. The second support portion S2 may support the second plate material 2 via the first resin material 3, as shown in FIG. 1(c), for example, or may directly support the second plate material 2. Here, the hollow space R indicates a region of the internal space Q excluding the region occupied by the spacer S.

[0046] The multiple third support parts S3 support the first support part S1 and the second support part S2 from the hollow space R. As shown in Fig. 1(d), for example, the multiple third support parts S3 support the load applied from the first support part S1 and the second support part S2 toward the hollow space R along the thickness direction Z, thereby holding the hollow space R.

[0047] Due to the configuration of these supporting portions S1 to S3, the spacer S can form a hollow space R between the first plate 1 and the second plate 2. In this case, a vacuum layer can be formed in the hollow space R. This can improve the thermal insulation properties of the vacuum insulation panel 100. Furthermore, because the supporting portions S1, S2 support the first plate 1 and the second plate 2, the hollow space R can be maintained even if one of the supporting portions of the plates 1, 2 is misaligned. This can prevent the thermal insulation properties of the vacuum insulation panel 100 from decreasing.

[0048] Furthermore, the multiple third support portions S3 may be plate-shaped, extending in one direction (first direction X in FIG. 1(d)), and integrally molded with the first support portion S1 and the second support portion S2, as shown in FIG. 1(c), for example. In this case, the first support portion S1, the second support portion S2, and the third support portion S3 can be easily manufactured by extrusion molding or the like. This can further improve the manufacturability of the vacuum insulation panel 100.

[0049] The spacer S is made of, for example, a plastic (synthetic resin) specified in ISO1043-1 or JIS K 6899-1. In the vacuum insulation panel 100, the plates 1 and 2 are supported by spacers S made of resin with a lower thermal conductivity than metal. Therefore, when a metal stronger than resin is used for the plates 1 and 2, the contact area between the metal plates can be reduced compared to when the spacer S is not used. This improves the durability of the vacuum insulation panel 100 while improving its insulation properties.

[0050] The spacer S is, for example, spaced apart from the first outer edge plate portion 12. In this case, the plate materials 1, 2 are supported by the spacer S made of a resin material having a lower thermal conductivity than metal, and since heat is not easily conducted from the outer edge side to the spacer S when the plate materials 1, 2 are joined, the spacer S is not easily deformed or evaporated in the internal space Q. This makes it possible to improve the thermal insulation property of the vacuum insulation panel 100 while improving manufacturability.

[0051] Regarding the distance between the spacer S and the first outer edge plate portion 12, the distance w3 from the third main surface f3 along the first direction X is, for example, about 10 to 20 mm. Also, the distance w4 from the fourth main surface f4 along the second direction Y is, for example, about 10 to 20 mm.

[0052] The dimensions of the spacer S are, for example, about 1460 mm in the longitudinal direction (first direction X in FIG. 1) of the first support part S1, about 372.5 mm in the lateral direction (second direction Y in FIG. 1), and 0.5 mm in thickness. The dimensions of the second support part S2 may be similar to those of the first support part S1.

[0053] The dimensions of the third support portion S3 are, for example, a length in the longitudinal direction (first direction X in FIG. 1) similar to that of the first support portion S1, a thickness in the second direction Y of about 0.5 mm, and a width w5 in the lateral direction (thickness direction Z in FIG. 1) of about 10 mm. Here, the width w5 of the third support portion S3 is similar to the separation width between the first support portion S1 and the second support portion S2. Furthermore, the width w6 of the multiple adjacent third support portions S3 is, for example, about 12 mm.

[0054] (First Modification of Vacuum Insulation Panel 100) <Second plate material 2> The second plate material 2 has a protruding bent portion T bent toward the standing plate portion 13 in a region between the first outer edge plate portion 12 and the spacer S facing the standing plate portion 13, as shown in Fig. 2(a) to Fig. 2(c), for example. In Fig. 2(a), the region of the bent portion T shown by the dashed line overlaps with the curved region of the standing plate portion 13 shown by the hatching in a plan view. The bent portion T is elastically deformed or plastically deformed by, for example, external pressure in the first direction X and the second direction Y. The bent portion T may be provided in a region between the first outer edge plate portion 12 and the spacer S facing the first main plate portion 11. The bent portion T may be provided between the first resin material 3 and the spacer S. Although not shown, the bent portion T may be a groove-like bent toward the opposite side of the standing plate portion 13.

[0055] Here, when the first resin material 3 is heated to bond the plate materials 1, 2 to manufacture the vacuum insulation panel 100, a large temperature difference occurs, with the temperature around the first outer edge plate portion 13 being approximately 200°C and the temperature around the first main plate portion 11 being approximately 20°C, and the difference in thermal expansion becoming large, which makes it easy for distortion to occur in the first plate material 1. If measures are not taken to prevent this distortion, internal stress will continue to act and the distortion will increase over time due to creep, and there is a risk that the first resin material 3 will eventually peel off from the plate materials 1, 2.

[0056] According to this modification, by providing the bent portion T in the second plate 2, the second plate 2 can deform in accordance with the deformation of the first plate 1 caused by heating, and wrinkles and cracks are less likely to occur on the surface, etc., of the second plate 2. This makes it possible to suppress a decrease in the thermal insulation property of the vacuum insulation panel 100.

[0057] Also, the bent portion T is separated from, for example, the standing plate portion 13. In this case, no heat conduction occurs due to contact with the standing plate portion 13 (first plate material 1), and deformation that does not follow the deformation of the standing plate portion 13, such as thermal expansion of the bent portion T itself, can be reduced. This makes it possible to further suppress deterioration of the thermal insulation property of the vacuum insulation panel 100.

[0058] The dimensions of the bent portion T are, for example, a width of the bent projection or groove of about 1 mm, and a height of the bent projection or groove of about 2 mm to 3 mm.

[0059] (Second Modification of Vacuum Insulation Panel 100) <First resin material 3> 3(a), for example, the first resin material 3 is provided on the entire surface (second main plate portion 21 and second outer edge plate portion 22) of the second plate material 2 facing the first plate material 1, which improves the workability of applying the resin to the surface of the second plate material 2 and reduces manufacturing costs. This also improves the flexibility of the arrangement of the first plate material 1. This improves the manufacturability of the vacuum insulation panel 100.

[0060] (Third Modification of Vacuum Insulation Panel 100) <Vacuum insulation panel 100> The vacuum insulation panel 100 may further include a second resin material 4, as shown in, for example, FIG. 3(b).

[0061] <Second resin material 4> The second resin material 4 is made of, for example, plastics (synthetic resins) specified in ISO1043-1 or JIS K 6899-1, and is made of a resin having a lower thermal conductivity than the first resin material 3. As the second resin material 4, for example, a silicone resin is used.

[0062] The second resin material 4 is interposed between the first resin material 3 and the second plate material 2, for example. In this case, compared to when only the first resin material 3 is interposed, it is easier to ensure the thickness of the resin material, and heat is less likely to be conducted between the plate materials 1 and 2. This can improve the thermal insulation of the vacuum insulation panel 100. The second resin material 4 may have a higher melting point than the first resin material 3. In this case, the second resin material 4 is less likely to melt than the first resin material 3, and is less likely to evaporate when the first resin material 3 is heated, making it easier to suppress the effect on the vacuum state of the internal space Q. This can suppress the deterioration of the thermal insulation of the vacuum insulation panel 100.

[0063] (Fourth Modification of Vacuum Insulation Panel 100) <Vacuum insulation panel 100> 3(c), the vacuum insulation panel 100 may have the outer edge bent portion 22a formed by crimping the first outer edge plate portion 12 and the second outer edge plate portion 22 through plastic deformation. In this case, the plates 1 and 2 can be joined more firmly than when they are joined only by the first resin material 3. This can improve the durability of the vacuum insulation panel 100.

[0064] When forming the outer edge bent portion 22a, the first resin material 3 may be deformed in the same manner as the second outer edge plate portion 22 to form the resin bent portion 3a. In this case, the first resin material 3 is included inside the outer edge bent portion 22a, and the plate materials 1 and 2 can be joined more firmly. This can further improve the durability of the vacuum insulation panel 100.

[0065] (Fifth Modification of Vacuum Insulation Panel 100) <Vacuum insulation panel 100> 3(d), the vacuum insulation panel 100 may be provided with a protective material 5 for protecting the first outer edge plate portion 12, the second outer edge plate portion 22, and the first resin material 3. In this case, the joints between the plates 1 and 2 are less susceptible to the effects of the external environment. This can improve the durability of the vacuum insulation panel 100.

[0066] The protective material 5 may be made of a known molding material, or may be made of a resin material. The protective material 5 may be formed, for example, in a U-shaped cross section, and holds the first outer edge plate 12 and the second outer edge plate 22 by sandwiching them on both sides of the U-shape. The protective material 5 may also be formed by solidifying a film that is dip-coated with an adhesive material such as wax or latex.

[0067] (Sixth Modification of Vacuum Insulation Panel 100) <Spacer S> As shown in FIG. 4(a), the spacer S has a first support portion S1 that supports the first plate material 1, a second support portion S2 that supports the second plate material 2, and a connecting portion S4 that connects the support portions S1 and S2 together.

[0068] The spacer S has, for example, a lattice-shaped connecting portion S4 as a base material, and has first support portions S1 protruding toward the first plate material 1 and second support portions S2 protruding toward the second plate material 2 at each intersection of the lattice. That is, in the spacer S, a plurality of first support portions S1 are connected to one first support portion S1 via connecting portions S4, and a plurality of second support portions S2 are connected to one second support portion S2 via connecting portions S4. In this case, the stress acting on each of the plate materials 1 and 2 can be dispersed by the plurality of supporting portions S1, S2. This can improve the durability of the vacuum insulation panel 100.

[0069] Furthermore, compared to the case where the flat connecting portion S4 is used, the material cost can be reduced and the supporting portions S1, S2 can be prevented from concentrating in one area, thereby improving the manufacturability of the vacuum insulation panel 100.

[0070] The spacer S forms a hollow space R, for example, by forming a hollow space R1 between a plurality of first support parts S1, the first plate material 1, and the connecting part S4, and by forming a hollow space R2 between a plurality of second support parts S2, the second plate material 2, and the connecting part S4.

[0071] At this time, the first support portion S1 supports the inner surface of the first plate 1, for example, with a convex curved surface. The second support portion S2 supports the inner surface of the second plate 2, for example, with a convex curved surface. That is, each support portion S1, S2 supports the first plate 1 and the second plate 2 at points. In this case, a vacuum layer can be formed with a larger volume in the hollow space R. This can further improve the thermal insulation properties of the vacuum insulation panel 100.

[0072] The dimensions of the spacer S are, for example, a width X1 between adjacent first support portions S1 and adjacent second support portions S2 along the first direction X of about 20 mm to 30 mm, and a width X1 between adjacent first support portions S1 and adjacent second support portions S2 along the second direction Y of about 20 mm to 30 mm.

[0073] As an example of the spacer S, a known knotted net having a lattice pattern in which warp and weft threads cross may be used. In this case, each support portion S1, S2 is formed by a knot of the knotted net. In this case, the effort required to adjust the arrangement of the spacer S can be reduced. This can improve the manufacturability of the vacuum insulation panel 100.

[0074] (Seventh Modification of Vacuum Insulation Panel 100) <Spacer S> The spacer S may be in the form of a net in which a plurality of meshes intersect, as shown in FIG. 4(b). The spacer S is, for example, a net in the form of a lattice in which a first support portion S1 of a weft thread extending along a first direction X and a second support portion S2 of a warp thread extending along a second direction Y intersect. The connecting portion S4 connects the supporting portions S1 and S2 at the intersections of the warp thread and the weft thread. In this case, the first supporting portion S1 and the second supporting portion S2 support each other along the thickness direction Z. Here, the lattice shape includes a rectangular lattice, a triangular lattice, a hexagonal lattice, a honeycomb structure, and the like. In addition, the spacer S may be in the form of a lattice in which the weft thread and the warp thread are woven alternately, so that the weft thread and the warp thread alternately form the first supporting portion S1 and the second supporting portion S2.

[0075] That is, in the spacer S, a plurality of second support portions S2 are connected to a single first support portion S1 via connecting portions S4, and a plurality of first support portions S1 are connected to a single second support portion S2 via connecting portions S4. In this case, the plurality of support portions S1, S2 can distribute stress acting on the plates 1, 2. This can improve the durability of the vacuum insulation panel 100.

[0076] The spacer S forms a hollow space R, for example, by forming a hollow space R1 between the multiple first support portions S1 and each of the plate materials 1 and 2, and forming a hollow space R2 between the multiple second support portions S2 and each of the plate materials 1 and 2.

[0077] As for the dimensions of the spacer S, for example, the width X2 between adjacent second support portions S2 in the first direction X is about 20 mm to 30 mm, and the width between adjacent first support portions S1 in the second direction Y is about 20 mm to 30 mm.

[0078] Examples of the types of woven nets used for the spacer S include plain weave nets, twill weave nets, raschel weave nets, moji nets, tin line nets, etc. The spacer S may also be a knotless net.

[0079] The spacer S may also be a plastic net in which the first support portion S1, the second support portion S2, and the connecting portion S4 are integrally formed by extrusion molding, cutting, pressing, or the like of a resin (polyethylene, polypropylene, polyvinyl chloride, etc.). In this case, the mesh of the spacer S is less likely to collapse, and stress acting on the plate materials 1, 2 is easily dispersed. This improves the durability of the vacuum insulation panel 100. Also, the effort required to adjust the position of the spacer S can be reduced. This improves the manufacturability of the vacuum insulation panel 100.

[0080] Examples of the spacer S include, for example, "Nakusa (registered trademark)", "Netron (registered trademark) sheet", and "Tricalnet (registered trademark)".

[0081] The spacer S may be formed in a lattice shape by intersecting a first support portion S1, which may be plate-shaped, rod-shaped, etc., extending along a first direction X, and a second support portion S2, which may be plate-shaped, rod-shaped, etc., extending along a second direction Y.

[0082] (Eighth Modification of Vacuum Insulation Panel 100) <Spacer S> As shown in FIG. 4(c), the spacer S has a flat connecting portion S4 as a base material, and has a first support portion S1 protruding toward the first plate 1 and a second support portion S2 protruding toward the second plate 2 on the flat surface. In this case, the support portions of the support portions S1 and S2 are less likely to shift compared to when a lattice-shaped connecting portion S4 is used, and stress acting on the plates 1 and 2 is more easily dispersed. This improves the durability of the vacuum insulation panel 100. Also, the effort required to adjust the arrangement of the spacer S can be reduced. This improves the manufacturability of the vacuum insulation panel 100.

[0083] The spacer S forms a hollow space R, for example, by forming a hollow space R1 between a plurality of first support parts S1, the first plate material 1, and the connecting part S4, and by forming a hollow space R2 between a plurality of second support parts S2, the second plate material 2, and the connecting part S4.

[0084] The dimensions of the spacer S are, for example, about 20 mm to 30 mm for the width X3 between adjacent first support portions S1 and adjacent second support portions S2 in the first direction X, and about 20 mm to 30 mm for the width X3 between adjacent first support portions S1 and adjacent second support portions S2 in the second direction Y.

[0085] The spacer S may be formed by, for example, performing press molding or embossing on a flat thermoplastic resin plate to form the support portions S1, S2 on both sides of the flat plate.

[0086] An example of the spacer S is "Raku-Raku Road" manufactured by Katsuron Co., Ltd.

[0087] (Ninth Modification of Vacuum Insulation Panel 100) <Spacer S> As shown in Fig. 4(d) to Fig. 4(e), the spacer S may have a shape in which a plurality of first support parts S1 and second support parts S2 are provided along a planar direction including the first direction X and the second direction Y, are provided alternately in a cross-sectional view, and are connected to each other via connecting parts S4, i.e., the surface of the spacer S may have an uneven shape like a wave. The spacer S has a first support part S1 protruding toward the first plate material 1, a second support part S2 protruding toward the second plate material 2, and a connecting part S4 connecting the first support part S1 and the second support part S2. Each of the support parts S1 and S2 is formed of a convex curved surface, and can point-support the first plate material 1 and the second plate material 2 at the vertices of the convex curved surface.

[0088] 4(d), the dimensions of the spacer S are, for example, such that the width X4 between adjacent first support portions S1 in the first direction X is about 20 mm to 30 mm, and the width Y4 between adjacent first support portions S1 in the second direction Y is about 20 mm to 30 mm. In addition, the width X4' between adjacent second support portions S2 in the first direction X is about 20 mm to 30 mm, and the width Y4' between adjacent second support portions S2 in the second direction Y is about 20 mm to 30 mm.

[0089] As shown in Figure 4(e), for example, the spacer S forms a hollow space R1 between the multiple first support parts S1, the first plate material 1, the opposite faces of the second support parts S2 (the faces facing the first plate material 1) and the connecting part S4, and forms a hollow space R2 between the multiple second support parts S2, the second plate material 2, the opposite faces of the first support parts S1 (the faces facing the second plate material 2) and the connecting part S4.

[0090] (Method of manufacturing the vacuum insulation panel 100) Next, an example of a method for manufacturing the above-mentioned vacuum insulation panel 100 will be described with reference to Figs. 5(a) and 5(b).

[0091] First, as shown in FIG. 5(a) to FIG. 5(b), the first plate 1 is placed on the hollow conductive tray 61 so that all sides of the first main surface f1 of the first outer edge plate 12 are in contact with each other and the upright plate 13 is oriented to rise toward the inside of the conductive tray 61. In addition, a spacer S is placed on the inner surface side of the first main plate 11, and the second plate 2 to which the first resin material 3 is applied is placed above the first plate 1 so that the third main surface f3 of the first outer edge plate 12 and the first resin material 3 face each other. At this time, in order to evacuate the internal space Q, for example, an operable motorized wedge (not shown) is interposed between the first outer edge plate 12 and the second outer edge plate 22 to form a gap between the first outer edge plate 12 and the second outer edge plate 22 that communicates with the internal space Q and the external environment. This completes the installation of the panel 101 before evacuation.

[0092] Here, depending on the thickness of the spacer S in the thickness direction Z, there may be cases where the first outer edge plate portion 12 and the second outer edge plate portion 22 of the second plate material 2 do not make good contact with each other, so a conductive tray 62 of the same material and shape as the conductive tray 61 may be disposed above the second plate material 2. In this case, the first outer edge plate portion 12 and the second outer edge plate portion 22 make good contact with each other by being sandwiched between the conductive trays 61, 62, which makes it easier to improve the airtightness of the internal space Q.

[0093] In addition, the panel 101 before evacuation with a gap formed between the first outer edge plate portion 12 and the second outer edge plate portion 22 is accommodated in the vacuum chamber C together with the conductive trays 61 and 62, and the inside of the vacuum chamber C is evacuated. At this time, the internal space Q is connected to the inside of the vacuum chamber C, and the internal space Q is also evacuated by evacuating the inside of the vacuum chamber C. After the internal space Q is evacuated, the above-mentioned electric wedge (not shown) is operated from outside the vacuum chamber C while the inside of the vacuum chamber C is kept vacuum, and the wedge is removed from between the first outer edge plate portion 12 and the second outer edge plate portion 22. At this time, the second plate material 2 loses support from the electric wedge and falls onto the first plate material 1. As a result, the first outer edge plate portion 12 and the second outer edge plate portion 22 can be brought into contact with each other without any gaps while the internal space Q is kept vacuum.

[0094] Thereafter, an external power source (not shown) is electrically connected to the conductive trays 61 and 62 to supply power to the conductive trays 61 and 62. As a result, the first resin material 3 is heated via the first outer edge plate portion 12 and the second outer edge plate portion 22 of the first plate material 1, and the first outer edge plate portion 12 and the second outer edge plate portion 22 are electrically welded together. This allows the internal space Q to be kept in vacuum even after it is removed from the vacuum chamber C.

[0095] The above steps complete the production of the vacuum insulation panel 100. The vacuum insulation panel 100 can be produced even more efficiently by further stacking the conductive trays 61, 62 and the pre-vacuum panel 101 in the vertical direction and electrically welding them together.

[0096] In addition, a jack (not shown) may be further disposed above the second plate 2 to press the conductive trays 61, 62 from above during electrical welding. In this case, the first outer edge plate 12 and the second outer edge plate 22 are firmly sandwiched between the conductive trays 61, 62, thereby making better contact, and it is easy to further improve the airtightness of the internal space Q. In addition, when the conductive trays 61, 62 and the pre-evacuation panel 101 are further stacked in the vertical direction, the panels can be securely sandwiched. This allows the manufacturing efficiency and quality of the vacuum insulation panel 100 to be improved.

[0097] According to this embodiment, the first resin material 3 having gas barrier properties is interposed between the first outer edge plate portion 12 of the first metal plate material 1 and the second outer edge plate portion 22 of the second metal plate material 2. That is, the metal plates can be joined together at a temperature lower than the welding temperature. Therefore, the metal plates 1 and 2 can be joined together at a lower cost and in a shorter time than with a welding tool. This can improve the manufacturability of the vacuum insulation panel 100. In addition, the first plate material 1 has the upright plate portion 13 formed with a curved surface. Therefore, the shell structure makes it easy to release the external pressure applied to the first plate material 1. This can improve the durability of the vacuum insulation panel 100.

[0098] Furthermore, according to this embodiment, the spacer S is made of a resin material and is spaced apart from the first outer edge plate portion 12 and the second outer edge plate portion 22. Therefore, while the plate materials 1, 2 are supported by the spacer S made of a resin material having a lower thermal conductivity than metal, heat is not easily conducted from the outer edge side to the spacer S when the plate materials 1, 2 are joined, so that the spacer S is not easily deformed or evaporated in the internal space Q. This makes it possible to improve the thermal insulation property of the vacuum insulation panel 100 while improving manufacturability.

[0099] In addition, according to this embodiment, the second resin material 4, which has a lower thermal conductivity than the first resin material 3, is interposed between the first outer edge plate portion 12 and the second outer edge plate portion 22. Therefore, it is easy to ensure the thickness of the resin material, and heat is less likely to be conducted between the plates 1 and 2. This can improve the thermal insulation of the vacuum insulation panel 100. In addition, when the melting point of the second resin material 4 is higher than the melting point of the first resin material 3, the second resin material 4 is less likely to melt than the first resin material 3, and the first resin material 3 is less likely to evaporate when heated, making it easy to suppress the influence on the vacuum state of the internal space Q. This can suppress the deterioration of the thermal insulation of the vacuum insulation panel 100.

[0100] According to this embodiment, the spacer S has a plate-shaped second support portion S2 that extends along the second plate material 2 to form a hollow space R between the first support portion S1 and the spacer S, and supports the second plate material 2, and a third support portion S3 that extends in one direction and is integrally formed with the first support portion S1 and the second support portion S2. This allows a vacuum layer to be formed in the hollow space R. This improves the thermal insulation of the vacuum insulation panel 100. In addition, the first support portion S1, the second support portion S2, and the third support portion S3 can be easily manufactured by extrusion molding or the like. This further improves the manufacturability of the vacuum insulation panel 100.

[0101] Furthermore, according to this embodiment, the first resin material 3 is interposed only between the first outer edge plate portion 12 and the second outer edge plate portion 22. This makes it easier to suppress the effect of the first resin material 3 being heated and evaporated on the vacuum state of the internal space Q. This makes it possible to suppress a decrease in the thermal insulation properties of the vacuum insulation panel 100.

[0102] Furthermore, according to this embodiment, the second plate 2 has a bent portion T between the first outer edge plate portion 12 and the spacer S. This allows the second plate 2 to deform in accordance with the deformation of the first plate 1 caused by heating, making it less likely to wrinkle or crack. This makes it possible to prevent the thermal insulation properties of the vacuum insulation panel 100 from decreasing.

[0103] Although some embodiments of the present invention have been described, these embodiments are presented as examples and are not intended to limit the scope of the invention. These novel embodiments can be implemented in various other forms, and various omissions, substitutions, and modifications can be made without departing from the spirit of the invention. These embodiments and their modifications are included in the scope and spirit of the invention, and are included in the scope of the invention and its equivalents described in the claims. [Explanation of symbols]

[0104] 100 Vacuum insulation panel 101 Vacuum front panel 1 1st plate material 11 1st main plate section 12 First outer edge plate 13 Standing plate part 2 Second plate material 21 2nd main plate section 22 Second outer edge plate 3. First resin material 4. Second resin material 5. Protective materials 61, 62 Conductive tray C. Vacuum chamber Q interior space R hollow space S Spacer T bend S1 1st support part S2 2nd support part S3 3rd support part S4 connection part X 1st direction Y Second direction Z thickness direction

Claims

1. A vacuum insulation panel comprising a pair of plates facing each other so that an internal space is formed between them, A first plate material made of metal; a second plate member made of metal that forms an internal space between the first plate member and the second plate member; a spacer that supports the first plate member and the second plate member from the internal space side; Equipped with The first plate material has a first outer edge plate portion on the outer edge side, an upright plate portion standing from the first outer edge plate portion and formed with a curved surface, and a main plate portion that is continuous with the upright plate portion and supported by the spacer, A first resin material having gas barrier properties is interposed between the first outer edge plate portion and a second outer edge plate portion on the outer edge side of the second plate material. A vacuum insulation panel that features:

2. The spacer is made of a resin material and is spaced from the first outer edge plate portion and the second outer edge plate portion.

2. The vacuum insulation panel according to claim 1 .

3. A second resin material having a lower thermal conductivity than the first resin material is interposed between the first outer edge plate portion and the second outer edge plate portion.

3. The vacuum insulation panel according to claim 1 or 2.

4. The spacer is A plate-shaped first support portion extending along the first plate and supporting the first plate; A plate-shaped second support portion that extends along the second plate member so as to form a hollow space between the first support portion and the second plate member and supports the second plate member; a plurality of third support portions that support the first support portion and the second support portion from the hollow space side; having The third support portions extend in one direction and are integrally formed with the first support portion and the second support portion.

3. The vacuum insulation panel according to claim 1 or 2.

5. The first resin material is interposed only between the first outer edge plate portion and the second outer edge plate portion.

3. The vacuum insulation panel according to claim 1 or 2.

6. The second plate member has a bent portion between the first outer edge plate portion and the spacer.

3. The vacuum insulation panel according to claim 1 or 2.

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